Foldable mailer

ABSTRACT

A foldable mailer suitable for mailing a vial comprising a single substrate formed of a base, a top panel, a right panel, a left panel, and a flap; wherein the top panel and the base are joined by a middle spacer, the left panel and the base are joined by a left spacer, the right panel and the base are joined by a right spacer, and the flap and the top panel are adjoined by a top spacer; and a vial holder adhered to the substrate, the vial holder comprising a foam block having a slot suitable for encasing a vial.

The present invention is a foldable mailer that is suitable for encasinga fragile item such as a glass vial containing a liquid and protectingthe encased item during transit such as via the postal service.

BACKGROUND

Shipping of fragile items such as small glass vials that contain aliquid, such as perfume and the like, is problematic since protection ofthe vial from breakage during shipment is a major concern. It is oftendesired to be able to provide a mailer for a glass vial that canadequately protect the vial, yet not be excessively bulky. Bulky mailersare undesirable since the cost of shipping will increase as the size andweight of the mailer increases.

Thus, it is desired to provide a relatively small, inexpensive, simpleand lightweight mailer suitable for protecting items such as glass vialsand the like during shipment by the postal service or by any of theprivate shipping companies. It is also desired to provide such a mailerthat is easy to produce and store.

SUMMARY

Provided is a foldable mailer suitable for mailing a vial comprising asingle substrate formed of a base, a top panel, a right panel, a leftpanel, and a flap; wherein the top panel and the base are joined by amiddle spacer, the left panel and the base are joined by a left spacer,the right panel and the base are joined by a right spacer, and the flapand the top panel are adjoined by a top spacer; and a vial holderadhered or otherwise affixed to the substrate, the vial holderpreferably comprising a foam block having a slot suitable for encasing avial.

An insert may be formed on an outer edge of the left panel and a matingslot may be cut near an edge of the right panel. The vial holder may beadhered to the top panel of the substrate, or in the alternative to thebase of the substrate.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 illustrates a plan view of a mailer for fragile items of thepresent invention, in unassembled form.

FIG. 2 illustrates the mailer of FIG. 1 in partially assembled form.

FIG. 3 illustrates the mailer of FIG. 1 in fully assembled form.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates a plan, unfolded view of the mailer 2. The mailer 2is preferably formed from a single substrate such as cardboard that isstiff enough to maintain its shape, bendable to form the finished maileras will be described, yet light enough to be mailed cheaply. Inaddition, the substrate should be suitable for printing such as foradvertising, mailing addresses and the like.

When unfolded as in FIG. 1, the mailer 2 is defined by several regionsas follows. A top panel 4 abuts a middle spacer 12, which in turn abutsa base 6. A left panel 8 abuts a left spacer 14, which in turn abuts thebase 6. A right panel 10 abuts a right spacer 16, which in turn abutsthe base 6. Also abutting the top panel 4 is a top spacer 18, which inturn abuts a flap 28. An insert 20 is formed on the outer edge of theleft panel 8, and a mating slot 22 is cut near the edge of the rightpanel 10 as shown.

A foam vial holder 24, which is rectangular in plan is affixed (such aswith adhesive) to the top panel 4. The foam vial holder 24 acts as ameans for holding the vial, and it has a slot 26 cut along its length,suitable for allowing a glass vial to be inserted within and held by thefoam 24 as shown by the dotted vial in FIG. 2. The biasing pressure ofthe foam will hold the vial in place without the need for any adhesive,but a small amount of adhesive (or tape) may be applied if desired toensure the vial does not fall out easily during transit.

Assembly of the mailer 2 may proceed as shown in FIG. 2 by folding alongthe lines of abutment as follows. The top panel 4 is folded downwardstowards the base along the two edges of the middle spacer 12 so that agap is formed between the top panel 4 and the base 6, the thickness ofwhich is defined by the width if the middle spacer 12. That thicknessshould be approximately equal to the thickness of the foam vial holder24, which will be a slightly larger than the diameter of the glass vialbeing shipped. This will ensure a good fit of the vial and protect itduring shipment. The top panel 4 is folded towards the base 6 as shownby the arrow 1 in FIG.2.

Next, the left panel 8 and the right panel 10 are then each folded overtowards each other, along the two edges of the left spacer 14 and theright spacer 16, respectively, as shown by the arrows 2 and 3, in thesame manner as the top panel 4 described above. The insert 20 may thenbe inserted within the mating slot 22, an as such the foam vial holder26 will be covered and protected by this assembly. Adhesive may be usedto secure the closure at this point.

The flap 28 may then be folded along the edges of the top spacer 18 soit overlaps the bottom portion of the base 6, and a small amount ofadhesive (or tape, etc.) may be used to secure the assembled package toprovide the completed assembly in FIG. 3. The name of the addressee andpostage may be imprinted on either side of the mailer as desired (orshipping labels may be used).

The dotted lines that define each of the spacers 12, 14, 16 and 18 maybe perforated, scored, or otherwise marked so as to make it easy for theuser to fold and assemble the mailer as described. Optionally, therecipient of the mailer may tear the top panel off from the rest of themailer at the middle spacer 12 and keep just the top panel 4 as a holderfor the vial while discarding the rest of the mailer. This is useful inparticular if decorative advertising is placed on the top panel 4.

In an alternative embodiment, the vial holder 26 may be located on thebase 6 instead of the top panel 4.

The foam block is described in the preferred embodiment as a means forholding the vial, but other means may be used instead of the foam blockif desired as long as it is secured within the assembled mailer asdescribed. In a further alternative, the vial or another object may beplaced within the assembled mailer without using the means for holdingthe vial as described, but such implementation may not be as secure.

In the non-limiting preferred embodiment, the size of the mailer is asfollows:

-   -   Width of left panel: 2.43 inches    -   Width of right panel: 2.64 inches    -   Width of all spacers: 31/64 inch    -   Width of base (and top panel): 4.75 inches    -   Height of base (and left and right panels): 6.75 inches    -   Height of top panel: 6.75 inches    -   Height of flap: ⅝ inch

These dimensions may of course be varied as desired.

Although the preferred embodiments have been described above by way ofexample only, it will be understood by those skilled in the art thatmodifications may be made to the disclosed embodiments without departingfrom the scope herein.

What is claimed is:
 1. A foldable mailer suitable for mailing a vialcomprising a single substrate formed of a base, a top panel, a rightpanel, a left panel, and a flap; wherein the top panel and the base arejoined by a middle spacer, the left panel and the base are joined by aleft spacer, the right panel and the base are joined by a right spacer,and the flap and the top panel are adjoined by a top spacer; and a vialholder adhered to the substrate, the vial holder comprising a foam blockcomprising a slot suitable for encasing a vial.
 2. The foldable mailerof claim 1 wherein an insert is formed on an outer edge of the leftpanel and a mating slot is cut near an edge of the right panel.
 3. Thefoldable mailer of claim 1 wherein the vial holder is adhered to the toppanel of the substrate.
 4. The foldable mailer of claim 1 wherein thevial holder is adhered to the base of the substrate.
 5. A method ofassembling a mailer from a single substrate formed of a base, a toppanel, a right panel, a left panel, and a flap, wherein the top paneland the base are joined by a middle spacer, the left panel and the baseare joined by a left spacer, the right panel and the base are joined bya right spacer, and the flap and the top panel are adjoined by a topspacer, the left panel comprising an insert at an outer edge thereof andthe right panel comprising a mating slot at an outer edge thereof; and avial holder adhered to the substrate, the vial holder comprising a foamblock comprising a slot suitable for encasing a vial, the methodcomprising the steps of: folding the top panel towards the base alongtwo edges of the middle spacer so that a gap is formed between the toppanel and the base, wherein the foam block is located in the gap;folding each of the left panel and the right panel towards each other,along the two edges of the left spacer and the right spacer,respectively, placing the insert within the mating slot, and folding theflap along the edges of the top spacer so it overlaps the bottom portionof the base.
 6. A foldable mailer suitable for mailing an itemcomprising a single substrate formed of a base, a top panel, a rightpanel, a left panel, and a flap; wherein the top panel and the base arejoined by a middle spacer, the left panel and the base are joined by aleft spacer, the right panel and the base are joined by a right spacer,and the flap and the top panel are adjoined by a top spacer.
 7. Themailer of claim 6 further comprising means for holding a vial.
 8. Themailer of claim 7 wherein the means for holding a vial comprises a foamblock adhered to the substrate, the foam block comprising a slotsuitable for encasing a vial.